Conduit bender

ABSTRACT

A powered conduit bending tool is configured to bend conduit. The tool comprises a housing, a motor contained within the housing, and a battery removably coupled to the housing to provide power to the motor. An output shaft extends from the housing and is driven by the motor to rotate about an axis. A head is coupled to the output shaft for rotation therewith. The head includes a curved channel for receiving the conduit. A guide is coupled to the housing and supported opposite the curved channel of the head. The guide includes a latching handle movable between a closed position and an open position. The motor drives the head to rotate relative to the housing so that the curved channel and the guide cooperate to bend the pipe.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/345,317, filed May 24, 2022, to U.S. Provisional Patent Application No. 63/323,151, filed Mar. 24, 2022, and to U.S. Provisional Patent Application No. 63/306,381, filed Feb. 3, 2022, the entire contents of which are all incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure relates to a tool for bending conduit. Conduit may include pipes, electrical metallic tubing (EMT), intermediate metal conduit (IMC), rigid metal conduit (RMC), rigid non metallic conduit (RNC), solid stock, rebar, or any other elongate material.

SUMMARY

In one embodiment, the disclosure provides a powered conduit bending tool configured to bend conduit. The tool comprises a housing, a motor contained within the housing, and a battery removably coupled to the housing to provide power to the motor. An output shaft extends from the housing and is driven by the motor to rotate about an axis. A head is coupled to the output shaft for rotation therewith. The head includes a curved channel for receiving the conduit. The tool includes a guide coupled to the housing and supported opposite the curved channel of the head. The guide includes a latching handle movable between a closed position, in which the conduit is secured to the head, and an open position, in which conduit is removable from the head. The motor drives the head to rotate relative to the housing so that the curved channel and the guide cooperate to bend the pipe when the latching handle is in the closed position.

In some embodiments, the motor is coupled to the output shaft by a drive train.

In some embodiments, the guide is mounted on a support arm extending between a first end and a second end, the first end including an opening configured to surround the output shaft.

In some embodiments, the first end of the support arm includes an eccentric support that moves the opening with respect to the first end. Movement of the opening with respect to the first end changes a dimension between the guide and the output shaft.

In some embodiments, the tool includes a set of controls configured to set a desired bend angle and an offset.

In some embodiments, the tool includes an optical sensor to sense the linear and rotational movement of the conduit as it moves along the curved channel.

In some embodiments, the tool includes an alignment laser that projects at least one alignment plane toward a tail end of the conduit.

In another embodiment, the disclosure provides a power tool configured to bend conduit, the power tool including a housing, a motor supported by the housing, a guide coupled to the housing, and a user interface for controlling the motor. The tool further includes an output shaft coupled to the housing and including a first end extending from the housing. The output shaft is driven by the motor to rotate about an output axis. A bender head is supported on the output shaft for rotation therewith, the bender head including a curved channel for receiving the conduit. The bender head is rotatable relative to the guide between a first position, in which the conduit is positionable in and movable along the curved channel, and a second position, in which the conduit is secured in the curved channel.

In some embodiments, the user interface includes a first actuator for moving the bender head from the first position to the second position. In some embodiments, the user interface includes a second actuator for further rotating the bender head relative to the guide from the second position to bend the conduit.

In some embodiments, in the second position, the guide is configured to contact the conduit to secure the conduit in the curved channel. In the first position, the guide is configured to be spaced from the conduit positioned in the curved channel.

In some embodiments, the guide is mounted to a guide support arm, the guide support arm having a first end mounted around the output shaft and a second end which receives the guide. The guide support arm is selectively secured to the housing so that the guide is fixed with respect to the housing during a loading and bending operation.

In another embodiment, the disclosure provides a conduit bending tool for bending conduit, the conduit bending tool including a handle extending between a first end and a second end, a bender head coupled to the first end, and a bender module coupled to the handle adjacent the head. The bender head includes a curved channel for receiving conduit. The bender module includes a module housing including an angled surface, a first sensor for sensing the orientation of the handle within a first vertical plane, wherein the curved channel is positioned within the first vertical plane, and a user interface positioned on the angled surface of the module housing. A controller is configured to received input from the first sensor, to determine a bend angle of the conduit, and to cause the user interface to display the bend angle.

In some embodiments, the bender module includes a second sensor for sensing an orientation of the handle in a second vertical plane, perpendicular to the first plane. In some embodiments, the controller is configured to receive input from the second sensor, to determine a tilt amount of the handle, and to cause the user interface to display a level indicator corresponding to a tilt amount.

In another embodiment, the disclosure provides a power tool configured to bend conduit including a housing, having a base and a tower, and a handle extending from the tower. The handle cooperates with the housing to define a working area at least partially between the base and the handle. An output shaft extends from the base into the working area and rotates about an output axis. A bender head is supported on the output shaft for rotation therewith and is configured to engage the conduit. A motor is positioned within the housing and configured to rotate the output shaft about the output axis. A battery receptacle is supported by the housing and is configured to removably receive a battery that provides power to the motor.

In some embodiments, the output axis intersects the handle. In some embodiments, the handle includes a user interface. In some embodiments, the housing includes a set of legs extending from the base, and wherein the power tool is alternately supported on a horizontal surface by the set of legs or supported above the horizontal surface by the handle. When the power tool is supported above the horizontal surface, the tower may be rested against a user in order to support the power tool during a bending operation.

In some embodiments the motor is positioned within the tower, and the tool further comprises a drive train mounted in the housing to couple the output shaft to the motor. In some embodiments the drive train includes a first planetary gear set, a bevel gear, and a second planetary gear set. The motor includes a motor shaft extending along a motor axis, and wherein the motor axis is perpendicular to the output axis of the output shaft. In some embodiments, the battery receptacle is located on the tower.

In some embodiments the base is rotatable with respect to the tower between a first position and a second position, wherein, in the first position, the output axis intersects the handle, and wherein, in the second position, the output axis does not intersect the handle.

In another embodiment a power tool is configured to bend conduit. The power tool includes a housing, a motor supported by the housing, and a handle extending from the housing and including a user interface for controlling the motor. An output shaft is coupled to the housing and includes a first end extending from the housing. The output shaft is driven by the motor to rotate about a output axis. A bender head is supported on the output shaft for rotation therewith, the bender head including a curved channel for receiving the conduit. A guide assembly is coupled to the housing, the guide assembly being movable between a locked configuration, in which the guide assembly is configured to secure the conduit in the curved channel, and an unlocked configuration, in which the conduit is removable from the curved channel.

In some embodiments, the guide assembly includes a guide and a latching handle pivotally coupled to the guide. In some embodiments, the guide includes a guide curved surface, and the latching handle includes a latch curved surface. In the locked configuration, the guide curved surface and the latch curved surface are in contact with the conduit secured in the curved channel and form a continuous guide path.

In some embodiments the guide assembly includes a guide arm extending between a first arm end and a second arm end. The first arm end is coupled to the housing and the second arm end is coupled to the guide. In some embodiments the first arm end of the guide arm is rotatably mounted around the output shaft such that the guide arm is rotatable with respect to the output shaft, and wherein the housing includes a locking latch for selectively securing the guide arm with respect to the housing. In some embodiments, the second arm end of the guide arm includes an eccentric support having an opening for coupling to the guide, and wherein the eccentric support is movable to adjust a position of the opening with respect to the guide arm.

In another embodiment, a power tool is configured to bend conduit. The power tool includes a housing, an output shaft, and a motor. The housing includes a tower and a base, the base being rotatable with respect to the tower. The output shaft extends from the base and is configured to receive a bender head with a curved channel for engaging conduit. The motor is positioned within the housing and configured to rotate the output shaft about an output axis. The base is rotatable between a first position in which the output axis extends in a first direction relative to the tower, and a second position in which the output axis extends in a second direction relative to the tower, the second direction being different than the first direction.

In some embodiments, the first direction is perpendicular to the second direction.

In some embodiments the tool further includes a working area adjacent the output shaft, wherein in the first position the working area is in a horizontal plane such that the bending operation occurs in the horizontal plane, and wherein in the second position the working area is in a vertical plane such that the bending operation occurs in the vertical plane. In some embodiments the tool further includes a handle extending from the tower, and wherein in the first position the handle at least partially overlies the base.

In some embodiments the power tool further includes a battery receptacle supported by the tower that is configured to receive a battery that provides power to the motor. In some embodiments the power tool further comprises a locking latch for securing the base in the first position and the second position.

In another embodiment, a bending system is configured to bend conduit. The system includes a power tool and a stand. The power tool includes a housing, a motor positioned within the housing, and an output shaft extending from the housing and driven by the motor to rotate about an axis. A bender head is rotatably coupled to the output shaft. The stand is configured to support the power tool above a surface. The stand includes a center column extending between a first end and a second end, the first end configured to couple to the power tool. A battery receptacle supported by the center column for receiving a battery to provide power to the motor of the power tool. A set of legs is coupled to the center column and engages the surface.

In some embodiments the battery receptacle is coupled to the center end of the center column. The power tool is movable to different orientations relative to the stand. The set of legs includes three legs arranged as a tripod.

In another embodiment a power tool is configured to bend conduit. The power tool includes a housing, a motor positioned within the housing, an output shaft extending from the housing and driven by the motor to rotate about an axis, and a bender head coupled for rotation with the output shaft and configured to engage a conduit during a bending operation. A guide is coupled to the housing and engages the conduit during the bending operation. A stand is coupled to the housing for supporting the housing above a support surface. The stand includes a battery receptacle for receiving a battery that provides power to the motor.

In some embodiments the housing is rotatably coupled to the stand for movement between a first position with the output shaft extending vertically, and a second position with the output shaft extending horizontally.

In some embodiments the power tool further includes a handle extending from the housing. A user input is configured to control operation of the motor, the user input being positioned on the handle.

In another embodiment, a power tool is configured to bend conduit. The power tool includes a housing, a motor positioned within the housing, an output shaft extending from the housing and driven by the motor to rotate about an axis, and a bender head coupled for rotation with the output shaft and configured to engage a conduit during a bending operation. A guide is configured to support the conduit during the bending operation. A guide support arm supports the guide in a variety of positions with respect to the output shaft. The guide support arm is rotatably coupled to the output shaft such that the guide support arm is rotatable with respect to the axis. In some embodiments, the power tool further includes a locking latch is used to selectively secure the guide support arm with respect to the housing.

In some embodiments the guide support arm includes a first end for coupling to the output shaft and a second end for coupling to the guide. The first end includes an opening and an eccentric support positioned within the opening. The eccentric support is movable within the opening. The eccentric supports includes a plate having a central opening, wherein the central opening receives the output shaft. The rotation of the plate causes movement of the central opening with respect to the first end.

In another embodiment, a bending tool is configured to bend conduit. The bending tool includes a handle extending along a handle axis to an end, and a bender head coupled to the end of the handle. The bender head includes a curved channel for receiving conduit. The bending tool includes a bender module having a sensor for sensing an orientation of the bender module and configured to generate a signal, a controller configured to receive the signal and determine a bend angle based on the signal from the sensor, and a display for displaying the bend angle.

In some embodiments the bender module is coupled to the handle at the end adjacent the bender head. In some embodiments the bender module is integrated into the bender head. In some embodiments the bender module further includes a power source, which may be a battery removably coupled to the bender module.

In some embodiments the bender module further includes a housing with an angled surface configured to be visible by a user holding the handle, and wherein the display is positioned on the angled surface.

In some embodiments the housing includes a first half and a second half movably coupled to the first half for movement between an open position and a closed position, wherein in the closed position the housing surrounds a portion of the handle, a portion of the bender head, or portions of both.

In another embodiment, a bending tool for bending conduit, the bending tool including a bender head and a laser module. The bender head includes a curved channel for receiving a conduit during a bending operation. The curved channel defines a bending plane. The bender head also includes a first mounting surface, and a second mounting surface spaced from the first mounting space. The laser module includes a laser configured to project a laser line. The laser module alternately couples to the first mounting surface and the second mounting surface. When the laser module is coupled to the first mounting surface, the laser line extends within the bending plane.

In some embodiments the laser module includes a mounting feature configured to secure the laser module to the bender head, and wherein the mounting feature includes a magnet.

In some embodiments, when the laser module is coupled to the second mounting surface, the laser line intersects the bending plane. In some embodiments the bender head includes a clamp for engaging conduit, and the first mounting surface is adjacent the clamp.

The features identified above may be used in any combination or individually. Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a handheld power tool engaging a conduit according to an embodiment.

FIG. 2 illustrates a portion of the tool of FIG. 1 including a drive train, a head, and a guide.

FIG. 3 is a side view of the drive train of FIG. 2 .

FIG. 4 is a partially exploded view of the power tool illustrating the head and the guide of FIG. 2 .

FIG. 5 is a rear perspective view of the tool of FIG. 1 .

FIG. 6 illustrates a step of operating the tool of FIG. 1 .

FIG. 7 illustrates a further step of operating the tool of FIG. 1 .

FIG. 8 illustrates a further step of operating the tool of FIG. 1 .

FIG. 9 illustrates a further step of operating the tool of FIG. 1 .

FIG. 10 illustrates a further step of operating the tool of FIG. 1 .

FIG. 11 illustrates a further step of operating the tool of FIG. 1 .

FIG. 12 illustrates the tool of FIG. 1 in an exemplary use environment.

FIG. 13 is a perspective view of a handheld power tool according to a further embodiment.

FIG. 14 illustrates a step of operating the tool of FIG. 13 .

FIG. 15 illustrates a further step of operating the tool of FIG. 13 .

FIG. 16 illustrates a further step of operating the tool of FIG. 13 .

FIG. 17 illustrates a further step of operating the tool of FIG. 13 .

FIG. 18 illustrates a further step of operating the tool of FIG. 13 .

FIG. 19 illustrates a further step of operating the tool of FIG. 13 .

FIG. 20 illustrates a further step of operating the tool of FIG. 13 .

FIG. 21 illustrates the tool of FIG. 13 in an exemplary use environment.

FIG. 22A illustrates an embodiment of a control for use with the tool of FIG. 13 .

FIG. 22B illustrates another embodiment of a control for use with the tool of FIG. 13 .

FIG. 23 is a perspective view of a power tool according to a further embodiment, the power tool being coupled to a stand.

FIG. 24 is a perspective view of the power tool of FIG. 23 .

FIG. 25 illustrates a drive train of the power tool of FIG. 23 .

FIG. 26 illustrates a step of operating the tool of FIG. 23 .

FIG. 27 illustrates a further step of operating the tool of FIG. 23 .

FIG. 28 illustrates a further step of operating the tool of FIG. 23 .

FIG. 29 illustrates a further step of operating the tool of FIG. 23 .

FIG. 30 illustrates a further step of operating the tool of FIG. 23 .

FIG. 31 illustrates a further step of operating the tool of FIG. 23 .

FIG. 32 illustrates the tool of FIG. 23 in an exemplary use environment.

FIG. 33 is a perspective view of a power tool according to a further embodiment, the power tool being coupled with a stand.

FIG. 34 is a perspective view of the power tool of FIG. 33 including an optical sensor.

FIG. 35 illustrates the optical sensor of FIG. 34 .

FIG. 36 illustrates an alignment feature for use with the power tool of FIG. 1 .

FIG. 37 is a perspective view of an alternate guide support arm for use with any of the described power tools.

FIG. 38 illustrates the guide support arm of FIG. 37 in a first configuration.

FIG. 39 illustrates the guide support arm of FIG. 37 in a second configuration.

FIG. 40 illustrates a conduit bender including a bender module.

FIG. 41 illustrates a schematic view of the bender module of FIG. 40 .

FIG. 42 illustrates the conduit bender of FIG. 40 in an operation position.

FIG. 43 illustrates another embodiment of a bender module with a removable battery.

FIG. 44 illustrates a still further embodiment of a bender module with a charging port.

FIG. 45 illustrates a removable bender module for coupling to a conduit bending tool.

FIG. 46 illustrates the removable bender module of FIG. 45 in an open position.

FIG. 47 illustrates the removable bender module of FIG. 46 in a closed position, coupled to a conduit bending tool.

FIG. 48 illustrates a laser module of an alignment system for use with a conduit bending tool.

FIG. 49 illustrates a head of a conduit bending tool with a first mounting surface that selectively receives the laser module of FIG. 48 .

FIG. 50 illustrates a head of a conduit bending tool with a second mounting surface that selectively receives the laser module of FIG. 48 and a third mounting surface that may selectively receive the laser module of FIG. 48 .

FIG. 51 illustrates the head of a conduit bending tool of FIG. 51 with a fourth mounting surface that may selectively receive the laser module of FIG. 48 .

FIG. 52 illustrates an alignment system in use with a conduit bending tool in one configuration.

FIG. 53 illustrates the alignment system of FIG. 52 in another configuration.

FIG. 54 illustrates a first step of an operation performed by a powered bending tool according to one embodiment.

FIG. 55 illustrates a second step of the operation of the tool of FIG. 54 .

FIG. 56 illustrates a third step of the operation of the tool of FIG. 54 .

FIG. 57 illustrates a fourth step of the operation of the tool of FIG. 54 .

FIG. 58 illustrates a final step of the operation of the tool of FIG. 54 .

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

It should also be noted that certain features are described in reference to certain embodiments but are not limited to application in that embodiment and may be incorporated into other embodiments, both explicitly disclosed and not disclosed.

DETAILED DESCRIPTION

Pipes or conduit are used in a variety of use cases that can require different configurations and shapes be created. A conduit bender is typically used to form the pipes into the desired shape. Typical conduit benders use the force applied by an operator's foot to bend the conduit along a head. This can be difficult if the operator is unable to apply the correct amount of force to bend pipes, especially stiff pipes. The process can also be imprecise, as the force from the operator's foot must be discontinued once the pipe has reached the desired bend angle, which is measured using indicators located on the head, beneath the operator's foot. Additionally, it can be a time consuming process to create multiple bends in multiple pipes and can be difficult to keep the orientation consistent for subsequent bends.

FIGS. 1-12 illustrate a powered conduit bending tool 10. The bending tool 10 can be used to bend conduit. Conduit may include pipes, electrical metallic tubing (EMT), intermediate metal conduit (IMC), rigid metal conduit (RMC), rigid non metallic conduit (RNC), solid stock, rebar, or any other elongate material. The bending tool 10 includes a housing 14 having a base 18 and a tower 22 extending up from the base 18. A set of legs 26 extends from the base 18 to support the housing 14 on a horizontal surface. The tower 22 includes a motor housing 30 containing a motor 34. The motor 34 may be an electric motor 34. In the illustrated embodiment, the bending tool 10 is battery powered and the tower 22 includes a battery receptacle 38 for receiving a battery 42. The battery 42 may be removable and rechargeable and is selectively electrically connected with the motor 34. In some embodiments the bending tool 10 may alternately or additionally include a power cord extending from the housing 14 for providing power to the motor 34. A handle 46 extends upwards and forwards from the tower 22. The handle 46 includes a grip portion 50 having a user interface 54. The user interface 54 includes a set of controls 58 and a trigger 62. The bending tool 10 may include a controller (not shown) to selectively provide power from the battery 42 to the motor 34 based on input from the user interface 54. In the illustrated embodiment, the bending tool 10 is handheld, so an operator can use the grip portion 50 to support the housing 14 above a surface. As shown in FIG. 12 , in some embodiments, the operator can utilize the grip portion 50 to support the housing 14 during operation and rest a rear of the motor housing 30 against their body to add support to the bending tool 10 as the bending tool 10 operates. In other embodiments, the bending tool 10 may be supported by the set of legs 26 on a horizontal surface during operation, or before or after operation.

The handle 46 cooperates with the base 18 and tower 22 to define a working area 70. The bending tool 10 includes an output shaft 74 extending upward from the base 18 into the working area 70. A bender head 78 is coupled to the output shaft 74 to rotate therewith. The bender head 78 may be removably coupled to the output shaft 74 and is interchangeable with any of a plurality of bender heads. The plurality of bender heads may include a variety of bender heads for accommodating different diameters of pipe, different stiffness of pipe, or for creating bends having different radii. In some embodiments, the bender head 78 is removable and can be coupled with a handle to operate as a typical conduit bender.

As best shown in FIG. 2 , the bender head 78 includes a front portion 82 and a rear portion 86. The rear portion 86 includes a central channel 90 for receiving an arm adapter 94. The arm adapter 94 extends between a first end 98 and a second end 102. The first end 98 includes a noncircular opening 106 for engaging the output shaft 74 and the second end 102 is mounted in the central channel 90. The front portion 82 includes an outer edge 110 defining a curved channel 114. The curved channel 114 may have a radius corresponding to a diameter of pipe intended to be bent by the bender head 78. At least a portion of the outer edge 110 extends along a semi-circular profile 118. The semi-circular profile 118 may have a radius corresponding to a radius of the resulting bend in the pipe. A holding clamp 122 extends from the front portion 82 and defines a contact surface 126 facing the curved channel 114. The bender head 78 may include a plurality of indicator markings 130, marking the sizes of the radii and the intended pipe. The plurality of indicator markings 130 may also include angle indicators 134 and an alignment indicator 138.

As shown in FIG. 4 , the bending tool 10 includes a guide assembly 140 movable between a locked configuration and an unlocked configuration. The guide assembly 140 includes a guide 142 mounted on a guide support arm 146. The guide support arm 146 extends between a first arm end 150 and a second arm end 154. The first arm end 150 includes an opening 158 surrounding the output shaft 74. In the illustrated embodiment, the guide 142 is mounted to the second arm end 154 of the guide support arm 146 by a fastener 162. The guide 142 includes a curved surface 166. The guide 142 is mounted so that the curved surface 166 is positioned opposite the curved channel 114, creating a pathway 170 for conduit. In some embodiments, the guide 142 is reversible and includes a second curved surface 174 having a different profile to accommodate different types and sizes of conduit. The guide assembly 140 further includes a latching handle 178 coupled to the guide 142. The latching handle 178 includes a third curved surface 182. In the illustrated embodiment, the latching handle 178 is pivotally mounted for rotation relative to the guide 142 between a locked position and an unlocked position. In the unlocked position, the latching handle 178 is pivoted away from the housing 14 to allow conduit to be installed in the bender head 78. In the locked position, the latching handle 178 is pivoted toward the housing 14 until the third curved surface 182 is generally aligned with the curved surface 166 of the guide 142, forming a continuous guide path. In some embodiments, the guide 142 is rotatable with the latching handle 178 between the locked position and unlocked position. In some embodiments, the latching handle 178 is integrally formed with the guide 142.

As illustrated in FIGS. 2-3 , a drive train 186 is mounted in the housing 14 to couple the motor 34 with the output shaft 74. The motor 34 includes a motor shaft (not shown) extending along a first axis 194 or motor axis 194. The drive train 186 includes a first planetary gear set 198 coupled to the motor 34. The first planetary gear set 198 may be a three stage planetary gear train and may transmit rotation from the motor 34 to a transfer shaft 202, which extends along the motor axis 194 toward the output shaft 74. The transfer shaft 202 includes a spiral bevel pinion 206 mounted at an end distal from the first planetary gear set 198. The spiral bevel pinion 206 engages a spiral bevel gear 210 to rotate the spiral bevel gear 210 about a second axis 214. The second axis 214 is perpendicular to the motor axis 194. The spiral bevel gear 210 is coupled to a second planetary gear set 218. The second planetary gear set 218 may be a single stage planetary gear train. The single stage planetary gear train transmits rotation from the spiral bevel gear 210 to an output gear 222. The output gear 222 is mounted for rotation about the second axis 214. The output gear 222 engages an internal ring gear 226 mounted for rotation about a third axis or output axis 230. The output axis 230 is parallel to, but spaced from, the second axis 214 and is collinear with the output shaft 74. The internal ring gear 226 is secured to the output shaft 74 for rotation therewith. When power is provided to the motor 34, rotation is transmitted through the first planetary gear set 198 to the transfer shaft 202 and spiral bevel pinion 206. The spiral bevel pinion 206 rotates about the motor axis 194 to rotate the spiral bevel gear 210 about the second axis 214. Rotation of the spiral bevel gear 210 is transmitted through the second planetary gear set 218 to the output gear 222. The output gear 222 rotates about the second axis 214, driving the internal gear to rotate about the output axis 230. The output shaft 74 rotates with the internal gear about the output axis 230.

While the drive train 186 is described as including a first planetary gear set 198, a spiral bevel gear 210, and a second planetary gear set 218, the drive train 186 is not limited to the disclosed configuration. Other drive train components may be used interchangeably with those disclosed above. Additionally, the number of stages in each of the planetary gear sets may be increased or decreased as appropriate for the type of motor and the desired output. For example, in some embodiments, the drive train 186 may include a direct drive, a belt drive, a cam drive, and the like.

The output shaft 74 extends along the output axis 230 between a first end 234, supported in the housing 14 for rotation relative to the housing 14, and a second end 238, extending from the housing 14 into the working area 70. The internal ring gear 226 is mounted adjacent the first end 234. The second end 238 includes a noncircular profile 242 corresponding to the noncircular opening 106 in the arm adapter 94 of the bender head 78. The noncircular profile 242 of the second end 238 is received in the noncircular opening 106 to rotatably couple the bender head 78 to the output shaft 74. The guide support arm 146 is supported on the output shaft 74 for rotation relative to the output shaft 74 and is mounted between the arm adapter 94 and the internal ring gear 226.

As best seen in FIG. 5 , the guide assembly 140 includes a locking latch 246. The guide support arm 146 is rotatably secured to the housing 14 by the locking latch 246. The locking latch 246 includes a locking lever 250 movable between a locked position, in which the guide support arm 146 is prevented from rotating with respect to the housing 14, and an unlocked position, in which the guide support arm 146 is able to rotate about the output shaft 74 relative to the housing 14. In the locking configuration of the guide assembly 140, the guide support arm 146 is secured to the housing 14 by the locking latch 246 in the locked position, and the latch handle 178 is moved to the locked position to form the continuous guide path.

With reference to FIGS. 6-11 , a method of using of the bending tool 10 is illustrated. As shown in FIG. 6 , with the latching handle 178 in the unlocked position a pipe 254 is installed in the pathway 170 defined between the curved channel 114 and the curved surface 166. Once the pipe 254 has been installed, the latching handle 178 can be moved (e.g., rotated) to the locked position, as shown in FIG. 7 . In the locked position, the pipe 254 is secured between the curved surface 166 and the curved channel 114. As shown in FIG. 8 , the space between the pipe 254 and the bender head 78 is such that the pipe 254 can be slid along the pathway 170 until the desired starting point of the bend is aligned with the alignment indicator 138 on the bender head 78. In some embodiments the pipe 254 is installed and aligned while the bending tool 10 is supported by the set of legs 26 on a surface. In other embodiments, the pipe 254 is installed and aligned while being supported by an operator via the grip portion 50.

Once the pipe 254 is installed and aligned, the bending tool 10 can be operated. The operator actuates the trigger 62 on the grip portion 50 which sends a signal to the controller. The controller then supplies the motor 34 with power from the battery 42, causing the motor shaft to rotate. Rotation of the motor 34 is transmitted through the drive train 186 to the output shaft 74, and by extension, the bender head 78. As the bender head 78 rotates with respect to the housing 14, the pipe 254 is held between the contact surface 126 of the holding clamp 122 and the curved channel 114 and is carried with the bender head 78. Movement of the bender head 78 moves the pipe 254 through the guide 142. The curved surface 166 of the guide 142 presses the pipe 254 against the curved channel 114, bending the pipe 254 into a curve, as shown in FIG. 9 . The operator depresses the trigger 62 until the pipe 254 is at the desired angle, as indicated by the angle indicators 134 on the bender head 78, which are clearly visible in the working area 70. Once the pipe 254 has been bent to the desired angle, the trigger 62 is released and the motor 34 is powered down.

To release the now bent pipe 254, the latching handle 178 is rotated to the unlocked position, as shown in FIG. 10 . The pipe 254 is then removed from the pathway 170 of the bending tool 10. The bending tool 10 is reset, as shown in FIG. 11 , by changing the direction of the motor 34 to operate in reverse, for example by using the set of controls 58 on the grip portion 50 and using the trigger 62 to rotate the drive train 186 in reverse, rotating the bender head 78 back to the starting position. The process can then be repeated with another pipe, or a subsequent bend in the same pipe.

As shown in FIG. 36 , the bending tool 10 may also include alignment lasers 290 to visually indicate a bending plane to an operator. The alignment lasers 290 may be mounted on the guide 142 or latching handle 178. The alignment lasers 290 project a first plane 294, perpendicular to the output axis 230, and a second plane 298, parallel to the output axis 230. The first plane 294 may be used to align the pipe 254 for a second bend in the same plane, such as for applications where the final pipe 254 will lay flush against a flat surface. The second plane 298 may be used to align the pipe 254 for a second bend in a perpendicular plane, such as for applications where the final pipe 254 will need to turn a corner. The pipe 254 may be rotated in the channel until the tail of the pipe 254 is completely within the desired plane. Then the latching handle 178 can be moved to the locked position to lock the pipe 254 in the desired orientation. In some embodiments, the alignment lasers 290 may only project one of the planes 294, 298, or may project more than two planes and/or planes at different angles relative to each other.

FIGS. 13-22B illustrate another handheld powered conduit bending tool 310. The tool 310 is similar to the bending tool 10 shown in FIGS. 1-12 and similar features are given similar reference numbers, plus 300. Features disclosed with reference to the tool 310 can be incorporated into the bending tool 10 and vice versa. The tool 310 includes a housing 314 with a base 318 and a tower 322. In the illustrated embodiment, the base 318 is rotatably mounted to the tower 322 to rotate a working area 370 between a horizontal plane and a vertical plane. The tool 310 includes a handle 346 that allows an operator to carry and support the tool 310 before, during, and after a bending operation. The base 318 is rotatable between a first working position in which an output shaft 374 extends from the base 318 in a first direction (e.g., a generally vertical direction), and a second working position in which the output shaft 374 extends from the base 318 in a second direction (e.g., a generally horizontal direction). A bender head 378 is mounted to the output shaft 374 for rotation therewith. Therefore, in the second working position the bender head 378 is rotatable about a horizontal axis.

In operation, the tool 310 receives a pipe 554 in substantially the same way as the bending tool 10. The pipe 554 is fed through a pathway 470 defined between the bender head 378 and the guide 442, as shown in FIG. 14 . FIG. 15 illustrates a latching handle 478 being moved to a locked position to secure the pipe 554 in the tool 310. Once the pipe 554 has been secured, the pipe 554 can be moved to align a desired starting point on the pipe 554 with an alignment indicator 438 on the bender head 378, as shown in FIG. 16 .

Once the pipe 554 has been installed and aligned, the tool 310 is ready to perform a bending operation. The handle 346 includes a set of controls 358 that allows the operator to input the required bend information. For example, in some embodiments the operator may use the controls 358 to set the desired bend angle, the thickness of the pipe, the type of conduit, the diameter of the conduit, and/or any other relevant information. In some embodiments, the input information is used to determine an additional offset angle to address the potential spring back. Spring back occurs when the conduits natural resilience restores the conduit after the bend, resulting in a bend that is less than the desired bend angle. By over-bending, or bending the conduit to an angle greater than the desired bend angle, the conduit naturally springs back, resulting in a bend of the correct angle. In some embodiments the offset may be manually accounted for by the operator entering a higher bend angle then the desired bend angle. In other embodiments, including this embodiment, the tool 310 uses the input from the controls 358 to determine an offset for each bend. The tool 310 utilizes stored information, such as a look-up table, to determine the required offset based on the bend information. For example, if the conduit bends matching the provided bend information tends to spring back from the bending operation by 10 degrees, the tool 310 sets an offset to 10 degrees, and add the offset to the desired bend angle to obtain the total bend angle. In other embodiments, the offset can be measured using different units. As shown in FIG. 17 , an operator uses the controls 358 of the user interface 354 to input the desired bend information for the bend operation. This step can also occur before the pipe 554 is loaded into the tool 310.

In narrow workspaces (such as that illustrated in FIG. 21 ) and especially for bends that occur in the middle of a long piece of pipe, it may be desirable to orient the tool 310 so that the pipe 554 moves in a vertical plane as it bends, rather than in a horizontal plane. In such cases, an operator can rotate the base 318 to the second working position after the pipe 554 has been installed, as shown in FIG. 18 .

Once the tool 310 has been oriented as needed, the operator can depress a trigger 362 to begin the bending operation. This activates a motor 334, which transmits rotation to the output shaft 374 through a drive train 486. The drive train 486 may be substantially the same as drive train 186. The output shaft 374 rotates the bender head 378, as shown in FIG. 19 , which cooperates with the latching handle 178 to bend the pipe 554. A controller uses the signals from the user interface 354 to automatically stop the motor 334 once the correct rotation of the bender head 378 corresponding to the input bend angle has occurred.

As shown in FIG. 20 , in cases where the base 318 has been rotated to the second position, once the pipe 554 has been bent, the base 318 can be returned to the first position. The pipe 554 can be released either before or after the base 318 is returned to the first position by releasing the latching handle 478. Then the tool 310 can be reset for the next operation.

As discussed above, the operator can use a user interface 354 including the set of controls 358 to set the desired angle and offset. In some embodiments, such as the embodiment shown in FIG. 22A, the user interface 354 includes a digital display and the control 358 in the form of a dial. The dial rotates in opposing directions to either increase or decrease a value of the desired angle and offset, as indicated on the digital display. In other embodiments, such as the embodiment shown in FIG. 22B, the user interface 354 may include the set of controls 358 having two labeled dials with positions that correspond to different values of angles and offsets. In still further embodiments, the user interface 354 may include other controls, such as pure digital controls, push buttons, sliding inputs, and more.

FIGS. 23-32 illustrate another embodiment of a powered conduit bending tool 610. The tool 610 is similar to the tools 10 and 310. Features disclosed with respect to the tool 610 can be incorporated into the tools 10 and 310, and vice versa. As shown in FIG. 23 , the tool 610 is mounted to a stand 858. The stand 858 provides hands-free support for the tool 610, freeing an operator's hands for guiding the pipe 854, or other related tasks, as shown in FIG. 32 . The stand may be a tripod including a center column, a head, and a set of three legs. The head may include mounting features for removably connecting to the tool 610. Alternately, the tool 610 may replace the head and be fixed to the center column. The legs may be collapsible, and the center column may include telescoping rods in order to easily transport and store the stand. In other embodiments, other types of stands may be used.

The power tool 610 includes a housing 614 including a base 618 and a handle 646. The handle 646 extends along a handle axis 862 that extends generally horizontally (when the stand 858 is upright) and does not intersect the base 618. In the illustrated embodiment, a motor housing 630 extends from a lower surface of the base 618 and contains a motor 634. In the illustrated embodiment, the housing 614 is mechanically supported by, and electrically connected to, the stand 858. A battery 642 may be removably mounted to the stand 858 to communicate power to the motor 634. In the illustrated embodiment, the battery 642 is coupled to a bottom of the center column, opposite the tool 610. In some embodiments the housing 614 may be removably supported on the stand 858, and the battery 642 and the power tool 610 may be directly coupled separately from the stand 858 to make the power tool 610 portable or handheld. The base 618 includes a user interface 654 including a display and a set of controls 658 in the form of push buttons adjacent the display. A controller may selectively couple the battery 642 with the motor 634 based on the input from the user interface 654. An output shaft 674 extends from a top surface of the base 618 in a generally vertical direction. A bender head 678 is mounted on the output shaft 674 for rotation therewith.

As shown in FIG. 25 , the tool 610 includes a drive train 786 connecting the motor 634 and the output shaft 674. The drive train 786 includes a first planetary gear set 798, which may be a six-stage planetary gear train. The first planetary gear set 798 transmits rotation from the motor 634 to an output gear 822, all along a motor axis 794. The output gear 822 is positioned in an internal ring gear 826 and drives rotation of the internal ring gear 826 about an output axis 830. The output axis 830 may be parallel to and offset from the motor axis 794. The internal ring gear 826 is secured to the output shaft 674 to rotate therewith. Therefore, rotation may be transmitted from the motor 634 through the drive train 786 to the output shaft 674 and thereby to the bender head 678.

With reference to FIG. 26 , the user interface 654 is used to set the parameters of the bending operation including, for example, a bend angle, an offset, the number of bends, or any other relevant information. As shown in FIG. 27 , a pipe 854 is then installed into a pathway 770 of the bender head 678 and a guide 742. A latching handle 778 is moved to a locking position to retain the pipe 854, as shown in FIG. 28 . The pipe 854 is then adjusted, as shown in FIG. 29 , to align a desired starting point with an alignment indicator 738.

A trigger 662 is positioned on the handle 646 and is actuated to start the bending operation, as shown in FIG. 30 . The trigger 662 is depressed constantly while the bending occurs and until the controller automatically stops the motor 634 based on the input from the user interface 654. In other embodiments, the operation may be controlled using the set of controls 658, such as by pressing a button to start the operation and providing an emergency stop button to stop the operation in the event something goes wrong. Once the pipe 854 has been bent, the pipe 854 is released from the tool 610 by moving the latching handle 778 to an unlocked position, as shown in FIG. 31 . The tool 610 is then reset as needed.

As shown in FIG. 32 , in some embodiments the housing 614 is rotatably supported on the stand 858 to allow the base 618 to tilt into a vertical plane.

FIGS. 33-35 illustrate another embodiment of a stand mounted powered conduit bending tool 910. The tool 910 is substantially similar to the tool 610, and only differences are discussed herein. Features discussed with reference to the tool 910 can be incorporated into the tools 10, 310, and 610 and vice versa. The tool 910 includes a housing 914 including a base 918 and a handle 946 with a trigger 962. The handle 946 extends along a handle axis 1162 that intersects the base 918. A user interface 954 is positioned at the junction between the handle 946 and the base 918.

With reference to FIGS. 34-35 , the tool 910 may include an optical sensor 1166 to monitor the movement of a pipe 1154 during a bending operation. While described and shown with reference to the tool 910 of FIG. 33 , the optical sensor 1166 may be implemented in any of the bending tools described herein.

In the illustrated embodiment shown in FIG. 34-35 , the optical sensor 1166 may be placed on a contact surface 1026 of a holding clamp 1022 on the bender head 978. The contact surface 1026 cooperates with a curved channel 1014 of the bender head 978 to secure the pipe 1154 during a bend operation. The optical sensor 1166 may be recessed from the contact surface 1026 so that the optical sensor 1166 does not contact the pipe 1154. In some embodiments, the optical sensor 1166 may be positioned on a curved surface of a guide. During the operation, the optical sensor 1166 can use imperfections and variations on an outer surface of the pipe 1154 to monitor if the pipe 1154 slips with respect to the holding clamp 1022. Additionally, between subsequent bending operations on the same pipe 1154, as the pipe 1154 travels through the bender head 978, the optical sensor 1166 can use the tracking features to determine if there is any rotation of the pipe 1154 as the pipe 1154 moves. This allows the operator to know if subsequent bends are in plane with each other. In some embodiments, the tool 910 may include a controller configured to display the slippage, feed, and rotation information to the operator via the user interface 954 or the controller may automatically adjust operating conditions based on the input of the optical sensor 1166.

FIGS. 37-39 illustrate an alternate embodiment of a guide support arm 1346 for use with a powered conduit bending tool. The guide support arm 1346 is similar to the guide support arm 146 and is described for use with the bending tool 10. However, the guide support arm 1346 could be incorporated in a similar manner into any of the tools described herein.

The bending tool 10 interchangeably receives a bender head 78 from a set of bender heads that accommodate different diameters of pipe as well as that change the radius of the resulting bend in a pipe. When the bending tool 10 is used with a bender head for creating a bend with different radii, the guide 142 may need to be in a different position relative to the output shaft 74 to create the correct bending force. For example, a bender head with a smaller radius would require that the guide 142 be closer to the output shaft 74 in order to press the pipe 254 into the curved channel 114. While it would be possible to switch out the guide support arm 146 along with the bender head, it would increase the difficulty of the changing process and increase the complexity by increasing the number of parts that must be matched and installed.

The guide support arm 1346 supports the guide 142 in a variety of positions relative to the output shaft 74. The guide support arm 1346 extends between a first end 1350 and a second end 1354 to which the guide 142 is mounted. The first end 1350 includes an opening 1474 for receiving an eccentric support 1478. The eccentric support 1478 includes a plate 1482 with a central opening 1358 formed in the plate 1482. The central opening 1358 fits around the output shaft 74 to secure the guide 142 to the housing 14. The plate 1482 is rotatably mounted in the opening 1474. Rotation of the plate 1482 within the opening 1474 moves the central opening 1358 with respect to the first end 1350. Thus, a distance between the central opening 1358 and the guide 142 is altered. In some embodiments, the plate 1482 may include a tab 1486. An operator may engage the tab 1486 to rotate the plate 1482 and adjust the distance. The tab 1486 may further serve as a locator, to lock the plate 1482 with respect to the first end 1350. In some embodiments, the first end 1350 may include indicator markings to indicate what type of bender head 78 is appropriate for each setting. In some embodiments, the plate 1482 may linearly slide, rather than rotate, between different positions.

FIGS. 40-42 illustrate a handheld conduit bending tool 1510 including a bender module 1540. In a standard handheld conduit bending operation, the operator may need to pause the bending operation frequently to use a level to check the current bend angle of the conduit, or to look at the indicator lines on the head to check the current bend angle. This can require stepping over the conduit and conduit bender, or require craning the operator's neck, to be able to see the other side of the head. This can be time consuming and result in inaccurate bend angles. With reference to FIG. 40 , the conduit bending tool 1510 includes a handle 1514 and a head 1518. The handle 1514 includes an elongate tube 1522 extending away from the head 1518. The head 1518 includes a central channel for receiving the handle and an outer edge 1530 defining a curved channel 1534. A holding clamp 1538 extends from the outer edge 1530 to mount the pipe in the curved channel 1534. The bender module 1540 is coupled to the handle 1514 adjacent the head 1518 and includes a housing 1544 having an angled surface 1548 including a user interface 1552 or display 1552. In the embodiment illustrated in FIG. 40 , the housing 1544 includes a mounting channel 1556 surrounding the handle 1514. The housing 1544 is fixed to the handle 1514 by the mounting channel 1556. The display 1552 is positioned on the angled surface 1548, so that when the conduit bending tool 1510 is positioned with the head 1518 adjacent a horizontal surface, such as the ground, the display 1552 is easily visible by an operator, as seen in FIG. 42 .

With reference to FIG. 41 , the bender module 1540 includes a measurement system 1560 including a controller 1564, one or more sensors 1568, and a power source 1572. The one or more sensors 1568 include at least a first orientation sensor 1576 and a second orientation sensor 1580. The first orientation sensor 1576 may sense the orientation of the handle 1514 relative to the ground in a first vertical plane. The first vertical plane includes the curved channel 1534 of the head 1518. The second orientation sensor 1580 may sense the orientation of the handle 1514 relative to the ground in a second vertical plane, perpendicular to the first plane. The first orientation sensor 1576 and second orientation sensor 1580 may include accelerometers, gyroscopes, or inertial measurement units. The one or more sensors 1568 use the center of the earth (or gravity) to establish a reference point, therefore, there is no need to calibrate the sensor for each bend operation. In some embodiments, the first orientation sensor 1576 may be one of a plurality of first sensors that senses the orientation of the handle 1514 in the first plane, and the second orientation sensor 1580 may the one of a plurality of second sensors that senses the orientation of the handle 1514 in the second plane. The one or more sensors 1568 are configured to generate signals and send the signals to the controller 1564. The controller

The controller 1564 is positioned within the housing 1544 and is electrically coupled to the power source 1572. In some embodiments, the power source 1572 is integrated into the housing 1544. In some embodiments, the power source 1572 is removably coupled to the housing 1544. The controller 1564 is programmed to receive the signals from the first orientation sensor 1576. The controller 1564 then uses the signals from the first orientation sensor 1576 along with information stored in the controller 1564 to determine a bend angle of the conduit based on the orientation of the handle 1514. The controller 1564 may use calculations, tables, or other known methods to determine the bend angle based on the input from the one or more sensors 1568. The controller 1564 is also programmed to output the bend angle to an angle portion 1584 of the display 1552. As seen in FIGS. 40-42 , the angle portion 1584 may display a numeral representation of the bend angle. In some embodiments, the angle may alternately be displayed graphically, or may be communicated in another way.

The controller 1564 is also programmed to receive the signal from the second orientation sensor 1580 and determine a tilt amount which can be categorized, for example, as within an acceptable range, out of plane in a first direction, or out of plane in a second direction. The controller 1564 then communicates with a level portion 1588 of the display 1552 to display one of a plurality of a level indicators 1592. As seen in FIGS. 40-42 , the plurality of level indicators 1592 includes a first level indicator 1594, a central level indicator 1596, and a second level indicator 1598. The central level indicator 1596 may be displayed when the orientation of the handle 1514 when viewed along the head 1518 is generally vertical, or the tilt amount is zero or near zero. The first level indicator 1594 may be displayed when the controller 1564 determines that the handle 1514 is tilted away from vertical, or out of plane, in a first direction, or when the tilt amount is negative. The second level indicator 1598 may be displayed when the controller 1564 determines that the handle 1514 is tilted away from vertical, or out of plane, in a second direction, or when the tilt amount is positive. In some embodiments, the central level indicator 1596 may move relative to the first and second level indicators 1594, 1598 to indicate the direction and degree of tilt.

With reference to FIG. 42 , in operation, a conduit 1500 is installed in the conduit bending tool 1510, and the conduit bending tool 1510 is positioned with the head 1518 adjacent a horizontal surface, such as the ground. In the initial position, the conduit 1500 extends from both sides of the head 1518 parallel to, or contacting, the ground. The handle 1514 extends generally vertically. The operator may place a foot or other stabilizing member on the conduit 1500 on the side of the head 1518 of the conduit bending tool 1510 opposite the holding clamp 1538. The operator then checks the level portion 1588 of the display 1552 to see which one of the plurality of level indicators 1592 is being displayed. If needed, the operator can move the handle 1514 until the central level indicator 1596 is displayed. The operator then lowers the handle 1514 toward the anchored end of the conduit 1500, and the head 1518 bends the conduit 1500 upward creating a tail. As the handle 1514 is lowered, the bend angle is displayed on the angle portion 1584 of the display 1552. Additionally, the operator can monitor the level portion 1588 of the display 1552, to ensure that the handle 1514 remains within the correct plane the entire operation. The operator can easily read the bend angle on the display 1552 without stepping over the conduit bending tool 1510 and can stop the bending operation once the desired angle has been reached.

The bender module 1540 allows the operator to easily assess the bend angle without having to use an external level and without having to step over the conduit bending tool 1510 or crane their necks to see the indicators positioned on the head 1518. The bender module 1540 also allows the operator to assess spring back of the conduit and compensate during the bending operation.

FIG. 43 illustrates a conduit bending tool 1510′ including another embodiment of a bender module 1540′ having a housing 1544′ with a different shape. In the illustrated embodiment, the housing 1544′ includes a first mounting channel 1556′ and a second mounting channel 1602. A removable battery 1604 is coupled to the housing 1544′ to act as the power source 1572′. The display 1552′ is still positioned on an angled surface 1548′ to provide easy visual access to the operator.

FIG. 44 illustrates a conduit bending tool 1510″ including another embodiment of a bender module 1540″ having a housing 1544″ with a different shape. The housing 1544″ includes a first mounting channel 1556″ and a second mounting channel 1602′. In the illustrated embodiment, the power source 1572″ is integrated into the housing 1544″, and a charging port 1608 is positioned to allow for on board charging of the power source 1572″. The charging port 1608 may be, for example, a USB-C port. The display 1552″ is still positioned on an angled surface 1548″ to provide easy visual access to the operator.

FIGS. 45-47 illustrate another embodiment of a bender module 1740. In the illustrated embodiment, the bender module 1740 is removably coupled to a conduit bender 1710 (FIG. 47 ). The bender module 1740 includes a housing 1744 with an angled surface 1748 including a display 1752. The bender module 1740 includes a measuring system 1760 that is substantially the same as measurement system 1560 and is not described in detail.

The illustrated housing 1744 includes a first half 1804 and a second half 1808 rotatably coupled to the first half 1804. In the illustrated embodiment, the angled surface 1748 includes a hinge 1812 that allows the second half 1808 to rotate relative to the first half 1804 about an axis 1816 that extends along the angled surface 1748. The housing 1744 defines a mounting channel 1756 formed between the first half 1804 and the second half 1808 of the housing 1744. In other embodiments, the first half 1804 and the second half 1808 may be completely separate from each other without the hinge 1812. In still other embodiments, the first half 1804 and the second half 1808 may be connected together by other means.

In operation, the bender module 1740 can be opened, as shown in FIG. 46 by pivoting the first half 1804 away from the second half 1808. The bender module 1740 can then be closed around a handle 1714 of the conduit bender 1710, as seen in FIG. 47 . In some embodiments, the bender module 1740 includes a latch for securing the first half 1804 of the housing 1744 relative to the second half 1808. Once the bender module 1740 is coupled to the conduit bender 1710, the bender module 1740 can be operated in the same way as described above with reference to bender module 1540.

In some embodiments, the mounting channel 1756 of the bender module 1740 may include an adjustable portion or adapter to allow the bender module 1740 to mount to handles with varying diameters. In some embodiments, the bender module 1740 may be coupled to a conduit bender 1710 using a different method, other than rotatable halves. For example, the bender module 1740 may fit on the end of the handle 1714 and may slide along the handle 1714 toward the head 1718. The bender module 1740 may be secured by tightening a collar, once in place. Other implementations may also be used.

FIGS. 48-53 illustrate an alignment system 1960 for use with a conduit bending tool 1910. The illustrated alignment system 1960 is described and illustrated in use with a handheld conduit bending tool 1910; however, the alignment system 1960 can be used with a powered conduit bending tool, such as those described previously, in substantially the same way. The alignment system 1960 is used to position conduit to create aligned subsequent bends.

As seen best in FIGS. 50-51 , the conduit bending tool 1910 includes a handle 1914 and a head 1918. The head 1918 extends between a front portion 1922 and a rear portion 1926. The front portion 1922 includes a curved channel 1928 for receiving a conduit 1900. The curved channel 1928 defines a bending plane. The rear portion 1926 couples to the handle 1914. The head 1918 includes a top surface 1930 and a bottom surface 1934. A holding clamp 1938 extends up from the bottom surface 1934 and secures the conduit 1900 in the curved channel 1928. The holding clamp 1938 is at a left side of the head 1918, and at the right side of the head 1918 is a footrest 1942 (FIG. 52 ). In a typical conduit bending operation, conduit 1900 is installed in the curved channel 1928, and the handle 1914 is lowered to the right, toward the footrest 1942, to bend the conduit 1900. The conduit 1900 can then be fed further through the curved channel 1928 and positioned to create an additional bend. It can be difficult to keep the conduit 1900 aligned in the curved channel 1928 in order to create the desired geometry. For example, when creating a U-bend using two 90 degree angle bends, the already bent pipe needs to be positioned so that a segment extends within the bending plane.

FIG. 48 illustrates the alignment system 1960 including a laser module 1964 having a housing 1968 and a laser 1972 positioned within the housing 1968. The laser 1972 generates a laser line 1976 that extends within an alignment plane. The housing 1968 includes a bottom surface 1980 having at least one alignment feature 1984 and a mounting feature 1988. The mounting feature 1988 may include a magnet, a recess or post configured to secure via snap fit, a threaded opening or threaded post, or any other appropriate mounting feature. In the illustrated embodiment, the mounting feature 1988 includes a magnet. In the illustrated embodiment, the at least one alignment feature 1984 includes a first aperture 1992 and a second aperture 1996. The second aperture 1996 is smaller than the first aperture 1992. In other embodiments, the at least one alignment feature 1984 may include one or more shaped profiles, tapered surfaces, or any other appropriate feature to prevent the laser module 1964 from being mounted in an incorrect orientation.

As seen in FIGS. 49-51 , the laser module 1964 can be coupled to one of a plurality of mounting surfaces 2004 on a head 1918 of the conduit bending tool 1910. Each of the mounting surface 2004 includes a head mounting feature 2008 and at least one head alignment feature 2012 corresponding to the at least one alignment feature 1984 of the laser module 1964. In the illustrated embodiment, the head mounting feature 2008 includes a magnetic surface of the mounting surface 2004. In the illustrated embodiment, the at least one head alignment feature 2012 includes a first post 2016 and a second post 2020. The first post 2016 is larger than the second post 2020, and generally corresponds to the first aperture 1992 on the laser module 1964. The second post 2020 generally corresponds to the second aperture 1996 on the laser module 1964. When the laser module 1964 is positioned on one of the mounting surfaces 2004, such as in FIG. 49 , the mounting feature 1988 of the laser module 1964 engages the head mounting feature 2008 to secure the laser module 1964 to the mounting surface 2004, or in other words the magnet 1988 secures the laser module 1964 to the magnetic surface 2004. The first post 2016 is received by the first aperture 1992 and the second post 2020 is received by the second aperture 1996 to ensure that the laser module 1964 is oriented correctly on the mounting surface 2004.

The laser module 1964 is coupled to a power source (not shown) in order to activate the laser 1972. In the illustrated embodiment, the laser module 1964 includes electrical contacts 2024 positioned in the first aperture 1992 and the second aperture 1996, and the head 1918 includes electrical contacts 2028 positioned on the first post 2016 and the second post 2020. In other embodiments, the electrical contacts 2024 may be positioned elsewhere on the laser module 1964. The electrical contacts 2024 may be coupled to the power source via external wires. In embodiments such as the conduit bending tool 1510, the laser module 1964 may be coupled to the power source 1572 through electrical contacts 2024.

As seen in FIG. 49 , in a first configuration of the alignment system 1960, the laser module 1964 is mounted to a first mounting surface 2030. The first mounting surface 2030 is positioned on a front side of the holding clamp 1938. As also seen in FIG. 52 , the laser module 1964 is positioned by the mounting features 1988 and the at least one alignment feature 1984 to project the laser line 1976 to the left of the head 1918 and forward of the curved channel 1928. In the first configuration, the alignment plane is parallel to and may be coplanar with the bending plane. The first configuration may be useful in creating offset bends in a conduit 1900.

As seen in FIG. 50 , in a second configuration of the alignment system 1960 the laser module 1964 is mounted to a second mounting surface 2032. The second mounting surface 2032 is positioned adjacent a rear portion 1926 of the head 1918. The laser module 1964 is positioned to project the laser line 1976 to the left of the head 1918 and rearward of the curved channel 1928. In the second configuration, the alignment plane is parallel to and may be coplanar with the bending plane. The second configuration may be useful in creating U bends in a conduit 1900.

With continued reference to FIG. 50 , in a third configuration of the alignment system 1960 the laser module 1964 is mounted to a third mounting surface 2036. The third mounting surface 2036 is positioned on a bottom surface 1934 of the head 1918. As seen in FIG. 53 , the laser module 1964 is positioned on the third mounting surface 2036 so that the laser line 1976 is projected to the left of the head 1918 and below the curved channel 1928, or in other words on the side of the bottom surface 1934. In the third configuration the alignment plane is perpendicular to the bending plane. The third configuration may be useful in creating a first type of corner bends.

With reference to FIG. 51 , in a fourth configuration of the alignment system 1960 the laser module 1964 is mounted to a fourth mounting surface 2040. The fourth mounting surface 2040 is positioned on a top surface 1930 of the head 1918. The laser module 1964 is positioned on the fourth mounting surface 2040 so that the laser line 1976 is projected to the left of the head 1918 and above the curved channel 1928, or in other words on the side of the top surface 1930. In the fourth configuration, the alignment plane is perpendicular to the bending plane. The fourth configuration may be useful in creating a second type of corner bends.

In operation, the laser module 1964 is coupled to one of the mounting surfaces according to the desired type of bend. After a first bend operation has been performed creating a bent end 1902, the conduit 1900 is moved through the curved channel 1928 until the location of the second bend is positioned in the curved channel 1928. The bent end 1902 of the conduit is rotated until the laser line 1976 is visible along a length of the bent end 1902. A second bending operation is then performed, creating a subsequent bend that is correctly aligned with the first bend.

The alignment system 1960 allows for multiple configurations by easily moving the laser module 1964 between the mounting surfaces 2004. The resulting bends are more accurate, and the process is simpler. The laser module 1964 may be used in combination with one of the bender modules described above. With such an arrangement, the power source of the bender module may also provide power to the laser module 1964.

FIGS. 54-58 illustrate another embodiment of a powered conduit bending tool 2110 including an electronic locking feature. The tool 2110 is similar to the tool 610, as well as the other tools disclosed herein. Features disclosed with respect to the tool 2110 can be incorporated into the other tools 10, 310, 610, 910, etc., and vice versa. While not shown in FIGS. 54-58 , the tool 2110 may be mounted to a stand to provide hands-free support, similar to the stand 858.

As seen in FIG. 54 , the tool 2110 includes a housing 2114 with a user interface 2154 having controls 2158 and a trigger 2162. A bender head 2178 is coupled to an output shaft 2174 powered by a motor to rotate the bender head 2178 with respect to a guide 2242. The guide 2242 is fixed with respect to the housing 2114.

As seen in FIG. 54 , the bender head 2178 may begin in a loading position. In operation, conduit C is positioned between a curved channel 2214 of the bender head 2178 and a holding clamp 2218 of the bender head 2178. As seen in FIG. 55 , the conduit C can then be moved within the channel 2214 to align a mark on the conduit C with an alignment marking 2238 on the bender head 2178. Once the conduit C is properly positioned, the operator can actuate a first actuator (e.g., a locking button 2101). As seen in FIG. 56 , when the locking button 2101 is actuated, the motor operates to rotate the bender head 2178 into a ready position, in which the conduit is clamped between the bender head 2178 and the guide 2242. The operator can then actuate a second actuator 2162 (e.g., a trigger) to begin the bend operation, as seen in FIG. 57 . During some operations, the operator may hold the trigger 2162 to manually control the bend angle. During other operations, the operator may set a desired bend angle using the user interface 2154 and pull the trigger 2162 once to start the bend operation and the tool 2110 may automatically stop rotating the bender head 2178 once the desired bend angle has been reached. During still further operations, the operator may set a desired bend angle and hold the trigger 2162 until the motor stops rotating the bender head 2178 once the desired bend angle has been reached.

As seen in FIG. 58 , once the bend operation has been completed, an operator may actuate a third actuator (e.g., an unlock button 2102), which rotates the bender head 2178 in reverse to the loading position. The conduit C can then be lifted out of the bender head 2178. Together, the three actuators 2101, 2102, 2106 define a user control 2158. In some embodiments, functionality of the actuators 2101, 2102, 2106 may be combined into fewer than three actuators (e.g., the button 2101 may both lock and unlock the bender head 2178, depending on the current position of the bender head 2178).

The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present subject matter. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of the one or more independent aspects as described.

Various features and advantages of the invention are set forth in the following claims. 

What is claimed is:
 1. A power tool configured to bend conduit, the power tool comprising: a housing including a base and a tower; a handle extending from the tower, the handle cooperating with the housing to define a working area at least partially between the base and the handle; an output shaft extending from the base into the working area and configured to rotate about an output axis; a bender head supported on the output shaft for rotation therewith, the bender head configured to engage the conduit; a motor positioned within the housing and configured to rotate the output shaft about the output axis; and a battery receptacle supported by the housing, the battery receptacle configured to removably receive a battery that provides power to the motor.
 2. The power tool of claim 1, wherein the output axis intersects the handle.
 3. The power tool of claim 1, wherein the handle includes a user interface.
 4. The power tool of claim 1, wherein the housing includes a set of legs extending from the base, and wherein the power tool is alternately supported on a horizontal surface by the set of legs, and supported above the horizontal surface by the handle.
 5. The power tool of claim 4, wherein when the power tool is supported above the horizontal surface, the tower may be rested against a user in order to support the power tool during a bending operation.
 6. The power tool of claim 1, wherein the motor is positioned within the tower, and further comprising a drive train mounted in the housing to couple the output shaft to the motor.
 7. The power tool of claim 6, wherein the drive train includes a first planetary gear set, a bevel gear, and a second planetary gear set.
 8. The power tool of claim 6, wherein the motor includes a motor shaft extending along a motor axis, and wherein the motor axis is perpendicular to the output axis of the output shaft.
 9. The power tool of claim 1, wherein the battery receptacle is located on the tower.
 10. The power tool of claim 1, wherein the base is rotatable with respect to the tower between a first position and a second position, wherein, in the first position, the output axis intersects the handle, and wherein, in the second position, the output axis does not intersect the handle.
 11. A power tool configured to bend conduit, the power tool comprising: a housing; a motor supported by the housing; a user interface for controlling the motor; an output shaft coupled to the housing and including a first end extending from the housing, the output shaft being driven by the motor to rotate about an output axis; a bender head supported on the output shaft for rotation therewith, the bender head including a curved channel for receiving the conduit; and a guide coupled to the housing; wherein the bender head is rotatable relative to the guide between a first position, in which the conduit is positionable in and movable along the curved channel, and a second position, in which the conduit is secured in the curved channel.
 12. The power tool of claim 11, wherein the user interface includes a first actuator for moving the bender head from the first position to the second position.
 13. The power tool of claim 12, wherein the user interface includes a second actuator for further rotating the bender head relative to the guide from the second position to bend the conduit.
 14. The power tool of claim 11, wherein, in the second position, the guide is configured to contact the conduit to secure the conduit in the curved channel.
 15. The power tool of claim 11, wherein, in the first position, the guide is configured to be spaced from the conduit positioned in the curved channel.
 16. The power tool of claim 11, wherein the guide is mounted to a guide support arm, the guide support arm having a first end mounted around the output shaft and a second end which receives the guide.
 17. The power tool of claim 16, wherein the guide support arm is selectively secured to the housing so that the guide is fixed with respect to the housing during a loading and bending operation.
 18. A power tool configured to bend conduit, the power tool comprising: a housing including a tower and a base, the base being rotatable with respect to the tower; an output shaft extending from the base and configured to receive a bender head with a curved channel for engaging conduit; and a motor positioned within the housing and configured to rotate the output shaft about an output axis; wherein the base is rotatable between a first position in which the output axis extends in a first direction relative to the tower, and a second position in which the output axis extends in a second direction relative to the tower, the second direction being different than the first direction.
 19. The power tool of claim 18, wherein the first direction is perpendicular to the second direction.
 20. The power tool of claim 18, further comprising a working area adjacent the output shaft, wherein in the first position the working area is in a horizontal plane such that the bend occurs in the horizontal plane, and wherein in the second position the working area is in a vertical plane such that the bend occurs in the vertical plane.
 21. The power tool of claim 18, further comprising a handle extending from the tower, and wherein in the first position the handle at least partially overlies the base.
 22. The power tool of claim 18, further comprising a battery receptacle supported by the tower and configured to receive a battery that provides power to the motor.
 23. The power tool of claim 18, further comprising a locking latch for securing the base in the first position and the second position.
 24. A bending system configured to bend conduit, the system comprising: a power tool including a housing, a motor positioned within the housing, an output shaft extending from the housing and driven by the motor to rotate about an axis, and a bender head rotatably coupled to the output shaft; and a stand configured to support the power tool above a surface, the stand including a center column extending between a first end and a second end, the first end configured to couple to the power tool, a battery receptacle supported by the center column for receiving a battery to provide power to the motor of the power tool, and a set of legs coupled to the center column and configured to engage the surface.
 25. The bending system of claim 24, wherein the battery receptacle is coupled to the second end of the center column.
 26. The bending system of claim 24, wherein the power tool is movable to different orientations relative to the stand.
 27. The bending system of claim 24, wherein the set of legs includes three legs arranged as a tripod.
 28. A power tool configured to bend conduit, the power tool comprising: a housing; a motor positioned within the housing; an output shaft extending from the housing and driven by the motor to rotate about an axis; a bender head coupled for rotation with the output shaft and configured to engage a conduit during a bending operation; a guide coupled to the housing and configured to engage the conduit during the bending operation; and a stand coupled to the housing for supporting the housing above a support surface, the stand including a battery receptacle for receiving a battery that provides power to the motor.
 29. The power tool of claim 28, wherein the housing is rotatably coupled to the stand for movement between a first position with the output shaft extending vertically, and a second position with the output shaft extending horizontally.
 30. The power tool of claim 28, further comprising a handle extending from the housing.
 31. The power tool of claim 30, further comprising a user input configured to control operation of the motor, the user input being positioned on the handle.
 32. A power tool configured to bend conduit, the power tool comprising: a housing; a motor positioned within the housing; an output shaft extending from the housing and driven by the motor to rotate about an axis; a bender head coupled for rotation with the output shaft and configured to engage a conduit during a bending operation; a guide configured to support the conduit during the bending operation; and a guide support arm configured to support the guide in a variety of positions with respect to the output shaft, the guide support arm being rotatably coupled to the output shaft such that the guide support arm is rotatable with respect to the axis.
 33. The power tool of claim 32, further comprising a locking latch for selectively securing the guide support arm with respect to the housing.
 34. The power tool of claim 32, wherein the guide support arm includes a first end for coupling to the output shaft and a second end for coupling to the guide.
 35. The power tool of claim 34, wherein the second end includes an opening and an eccentric support positioned within the opening.
 36. The power tool of claim 35, wherein the eccentric support is movable within the opening.
 37. The power tool of claim 35, wherein the eccentric support includes a plate having a central opening, wherein the central opening receives the output shaft, and wherein rotation of the plate causes movement of the central opening with respect to the first end.
 38. A bending tool configured to bend conduit, the bending tool comprising: a handle extending along a handle axis to an end; a bender head coupled to the end of the handle, the bender head including a curved channel for receiving conduit; a bender module including: a sensor for sensing an orientation of the bender module and configured to generate a signal, a controller configured to receive the signal and determine a bend angle based on the signal from the sensor, and a display for displaying the bend angle.
 39. The bending tool of claim 38, wherein the bender module is coupled to the handle at the end adjacent the bender head.
 40. The bending tool of claim 38, wherein the bender module is integrated into the bender head.
 41. The bending tool of claim 38, wherein the bender module further includes a power source.
 42. The bending tool of claim 41, wherein the power source is a battery removably coupled to the bender module.
 43. The bending tool of claim 38, wherein the bender module further includes a housing with an angled surface configured to be visible by a user holding the handle, and wherein the display is positioned on the angled surface.
 44. The bending tool of claim 38, wherein the housing includes a first half and a second half movably coupled to the first half for movement between an open position and a closed position, and wherein in the closed position the housing surrounds a portion of the handle, a portion the bender head, or portions of both.
 45. A bending tool for bending conduit, the bending tool comprising: a bender head including a curved channel for receiving a conduit during a bending operation, the curved channel defining a bending plane, a first mounting surface, and a second mounting surface spaced from the first mounting surface; and a laser module including a laser configured to project a laser line, the laser module alternately couplable to the first mounting surface and the second mounting surface, wherein when the laser module is coupled to the first mounting surface, the laser line extends within the bending plane.
 46. The bending tool of claim 45, wherein the laser module includes a mounting feature configured to secure the laser module to the bender head.
 47. The bending tool of claim 46, wherein the mounting feature includes a magnet.
 48. The bending tool of claim 45, wherein when the laser module is coupled to the second mounting surface, the laser line intersects the bending plane.
 49. The bending tool of claim 45, wherein the bender head includes a clamp for engaging the conduit, and wherein the first mounting surface is adjacent the clamp. 